JP2693817B2 - Fiber-reinforced coating material and manufacturing method thereof - Google Patents

Description

TECHNICAL FIELD The present invention relates to a fiber-reinforced coating material and a method for producing the same,
In particular, the present invention relates to a fiber reinforced coating material mainly composed of resin mortar or resin concrete and a method for producing the same.

<Conventional technology> Conventionally, methacrylic resin-based resin mortar and resin concrete have been used as emergency repair materials for factory floors, road pavements, etc. because of their excellent chemical resistance, ultra-fast curing, and low-temperature workability. Has been. However, if the base is not sufficiently dried, peeling may occur after construction, and there is a risk of breakage when subjected to repeated impact loads. For this reason, measures have been taken to increase the impact strength by increasing the coating floor thickness.

However, if it is applied thickly at one time, there is a problem that heat generation and shrinkage amount accompanying the curing of the resin increase and cracking occurs.

On the other hand, these days, chopped strands of glass fiber or silica fiber are mixed and reinforced in joint materials such as bricks and tiles, resin mortar used as a lining material for heat insulation and corrosion protection of reaction tanks, etc. A technique has been proposed (Japanese Patent Laid-Open No. 59-122529).

In addition, there are two types of wall materials that have excellent flame retardancy, soundproofing, waterproofing, and heat retention: cement mixed with glass fiber and cement mixed with wood chips such as wood shreds and wool. Layer-integrated ones have also been proposed (Shokaisho 62-136321).
issue).

<< Problems to be Solved by the Invention >> Therefore, the resin mortar and resin concrete described above are mixed with the glass fiber, silica fiber, or wood chips described above to make the best use of the characteristics of the resin mortar or resin concrete, and to give an impact. It is conceivable to improve the strength and crack resistance and use this as not only the above-mentioned emergency repair material but also, for example, a coating floor material.

However, the type, properties, or mixing ratio of the fibers used in the joint material, the lining material of the reaction tank, or the wall material cannot be directly applied as the floor material.

As is well known, factory floors, roads, and floors of other general buildings and houses are constantly subjected to large loads and also subjected to repeated impact loads. Under such a load, it is easily broken depending on the type and properties of the fiber, and easily peeled off or cracked depending on the mixing ratio.

Furthermore, in the case of road pavement, etc., super fast hardening and low-temperature workability are essential, and it is compatible with resin mortar and resin concrete having such characteristics, and a type of fiber that can make full use of such characteristics. , Properties and blending ratio.

The present invention has been made in view of the above points, and its object is to have excellent chemical resistance, super-fast curing property, and low-temperature workability, tolerant of repeated impact load, and to generate heat during curing and A fiber-reinforced coating material having a small shrinkage amount and a method for producing the same are proposed.

<< Means for Solving the Problems >> In order to achieve the above object, the fiber-reinforced coating material of the present invention has a particle diameter of 0.3 mm or less and silica sand as a dispersion material and a fiber length of 1
A mixture of 0 mm or less of carbon fibers dispersed and mixed, which is a mixture of a resin and mortar or concrete, or a resin alone, wherein the carbon fiber content is 1 wt% with respect to the silica sand. % Or more and 10 wt% or less with respect to the resin.

Further, the method for producing a fiber-reinforced coating material according to another invention of the present application, the particle diameter is 0.3 mm or less silica sand as a dispersion material and the fiber length is 1
After the carbon fiber of 0 mm or less is dispersed and mixed as a first step without adding water, the dispersion mixture is mixed with a resin and mortar or concrete, or a resin alone is mixed as a second step. It is characterized by that.

<< Action >> In the fiber-reinforced coating material according to the present invention, the carbon fiber acts to reduce the amount of heat generation and the amount of shrinkage during curing of the resin mortar or resin concrete.

This is because the linear shrinkage of methacrylic resin is 0.2%, whereas the linear shrinkage of carbon fiber is as small as 0.01%.
This is because the effect of restraining the shrinkage due to the heat generated by the resin curing occurs.

Further, since carbon fiber has excellent low-temperature toughness, and also has flexibility and ductility, it increases the bending / compressive strength and maximum elongation of the fiber-reinforced coating material according to the present invention, and improves the deformability and the resistance to repeated impact load. Has an increasing effect.

Moreover, since carbon fibers are durable and resistant to acids and alkalis, they act to remarkably improve the chemical resistance and durability of the fiber-reinforced coating material according to the present invention.

However, the carbon fiber has a very small fiber diameter (diameter 13 μ
m), since the surface area is very large, if a large amount of this is blended, the amount of resin will be insufficient, and this will cause poor curing. If the difference in specific gravity between the carbon fiber and silica sand is too large, the dispersibility of the carbon fiber decreases, so the content should be 1 wt% or more relative to the silica sand and 10 wt% or less relative to the resin.

Further, if the fiber length of the carbon fiber is too long, the trowel separation during coating operation becomes poor and the workability is significantly reduced,
Use fibers with a fiber length of 10 mm or less.

Furthermore, since silica sand having a particle size of 0.3 mm or less is mixed as a dispersant, carbon fibers can be easily dispersed, and silica sand is a suitable aggregate because it adheres well to mortar, and after curing the resin mortar. Can obtain sufficient strength as a coating material such as a floor material.

Further, in the method for producing a fiber-reinforced coating material according to the present invention, as a first step, silica sand as a dispersant and carbon fibers having the above blending amount are dispersed and mixed by a so-called dry method in which water is not added in advance, and then a second step. As this dispersion mixture is mixed with resin mortar or resin concrete, a mixture of a resin and mortar or concrete, or a resin alone, the dispersion mixture can be maintained in a powdery state without forming lumps.

That is, in the first step, when the wet method is used in which water is added when silica sand and carbon fibers are mixed, the relationship between the carbon fibers is larger than the relationship between the carbon fibers and silica sand, so that the contact with water The surface tensions tend to facilitate mutual adsorption.

Specifically, regarding the relationship between the carbon fibers, since the carbon fibers are filamentous, when they contact each other, the contact portion has a linear shape. On the other hand, in the relationship between the carbon fibers and the silica sand, the shape of the contact portion between these is a dot shape, and thus the contact area is significantly smaller than the relationship between the carbon fibers. Therefore, in a so-called wet method in which water is not added, the adhesion between the carbon fibers becomes higher than the adhesion between the carbon fibers and silica sand, and the carbon fibers are adsorbed even if silica sand that is a dispersant is mixed, So-called fiber balls tend to be generated.

On the other hand, in the case of the dry method in which water is not added as in the present invention, it is possible to suppress the increase in the adhesiveness between the carbon fibers, and to secure the dispersion effect of the dispersant to effectively increase the carbon fibers. Can be loosened.

As a result, in the second step, short carbon fibers having a fiber length of 10 mm or less can be easily and uniformly mixed into the resin mortar or resin concrete. Moreover, the power for each of these two-stage mixing operations is extremely small and sufficient, and the mixing time may be short.

That is, according to the fiber-reinforced coating material and the method for producing the same of the present invention, when the carbon fiber and silica sand are dispersed and mixed, the carbon fiber and silica sand can be uniformly and easily mixed, and the carbon fiber and silica sand can be mixed. Was mixed as the first stage,
When a resin is mixed with mortar or concrete or a resin alone (hereinafter, also referred to as "resin matrix") is further mixed as a second step, it can be uniformly dispersed in the resin matrix or the like. . Therefore, at the time of these two stages of mixing, the power of each mixing operation is extremely small and sufficient, and the mixing time is short.

Further, in the coating work, the trowel separation becomes good and the workability can be improved.

Furthermore, after the fiber-reinforced coating material is hardened, silica sand as a dispersant becomes a suitable aggregate that adheres well to the resin and mortar, and it also increases the maximum elongation of the coating material, deformability and repeated impact resistance. The load can be increased, and as a result, the strength of the floor material can be improved.

In the fiber reinforcement coating material and the method for producing the same according to the present invention described above, as the resin, methacrylic resin, epoxy resin, polyurethane resin, polyester resin, vinyl ester resin or the like is used.

<Example> An example of the fiber-reinforced coating material of the present invention will be described in detail below. This fiber-reinforced coating material is a mixture of silica sand as a dispersant having a particle diameter of 0.3 mm or less and a carbon fiber having a fiber length of 10 mm or less dispersedly mixed, a mixture of a resin and mortar or concrete, or a resin. It is made by mixing either of the individual substances, that is, the resin matrix, and the carbon fiber content is 1 wt% or more with respect to silica sand and 10 w with respect to the resin.
It should be t% or less.

In this example, the fiber-reinforced coating material was obtained by using a part of the aggregate (sand) of a commercially available methacrylic resin-based flooring material [trade name Acrytone Floor manufactured by Mitsubishi Rayon Co., Ltd.] Carbon short fibers with a fiber length of 3 mm are added to silica sand (particle diameter 0.3 mm or less).
A fiber-reinforced coating material is manufactured by substituting the dry mixed powder of short carbon fibers homogeneously dispersed at 3 wt% and mixing with a commercially available hand mixer.

This product name, Acritone Floor, is a so-called resin concrete that is made by mixing resin and aggregates. As is well known, its components are MMA (methyl methacrylate monomer) as resin, sand as aggregate and curing agent. As BPO
A composite initiator such as (benzoyl peroxide) is included.

Therefore, the fiber-reinforced coating material of this example obtained by substituting a part of the aggregate of the acritone floor having such a component with the carbon short fiber dry mixed powder is carbon fiber and No. 8 silica sand as the dispersion material. In addition to MMA as a resin, sand as an aggregate, and BPO as a curing agent, the mixing ratio is as shown in Table 1.

The molded product of the fiber-reinforced coating material thus blended is cast in a commercially available steel mold (4 × 4 × 16 cm) in this example, and is molded at room temperature (20 ± 3 ° C.) for 24 hours. It is manufactured by demolding after curing. The bending / compressive strength of this molded body was measured using a precision universal testing machine [Autograph manufactured by Shimadzu Corporation] at a test speed of 0.5 mm / mi.
n is performed according to JIS R5201.

Further, during curing (curing) of the molded body, a thermocouple was embedded in the molded body, and a calorific value at the time of curing was measured by a digital strain meter [Tokyo Sokki Co., Ltd., trade name TDS-301]. It was measured.

Further, a strain gauge (measurement length 30 mm) was attached to the above-mentioned molded body after demolding, and the strain generated during the above bending test was recorded by the above digital strain measuring instrument.

Table 2 shows the results. In Table 2, those in which carbon fiber and No. 8 silica were not mixed were designated as No. 1, and the molded bodies relating to the fiber-reinforced coating material of the present invention were designated as No. 2 to 4. The values in the table are average values for 10 molded articles.

As is clear from Table 2, short carbon fibers are not mixed.
Comparing No. 1 with No. 2 to 4 in which short carbon fibers were mixed in silica sand in an amount of 1 wt% or more and resin in an amount of 10 wt% or less, the amount of short carbon fibers mixed increased. As a result, the amount of heat generation and shrinkage decreased, the bending / compression strength and maximum elongation increased, and conversely the elastic modulus decreased.

In this example, resin concrete in which aggregate was mixed with resin was used as the resin matrix, and the carbon fiber and the dispersant were mixed therein. However, the present invention is not limited to this, and other resin may be used as the resin matrix. For example, carbon fiber or the like may be mixed with so-called polymer mortar containing a cement component such as ordinary Portland cement.

Next, a comparative molded body molded by changing the compounding, the fiber length of the carbon fiber or the manufacturing procedure, and manufactured in this example.
Comparative examples for comparing No. 2 to 4 molded bodies will be described below.

Comparative Example 1 A comparative molded body was manufactured in exactly the same manner as the molded bodies of Nos. 2 to 4 except that the amount of the short carbon fiber dry mixed powder was replaced so that the carbon short fiber was 10.5 wt% with respect to the resin. However, it was not completely cured after curing for 24 hours, and it was found that the upper limit of the blending ratio of short carbon fibers was 10 wt% with respect to the resin.

Comparative Example 2 Nos. 2 to 4 except that carbon short fibers having a fiber length of 10.5 mm were used.
A comparative molded product was produced in exactly the same manner as the molded product, but it was extremely difficult to pour an appropriate amount into each mold due to poor cutting of the mixture during the continuous pouring operation into the mold.

Then, when the mixture taken out from the hand mixer was painted with a trowel, it was found that the trowel separation was poor and the workability was not good.

Therefore, it became clear that the upper limit of the fiber length of carbon fiber is 10 mm.

Comparative Example 3 In Comparative Example 3, the compounding ratio was the same as that of the No. 2 to 4 molded bodies, and the mixing procedure was changed to manufacture the comparative molded body.
That is, short carbon fibers were mixed with a methacrylic resin-based flooring material, and then No. 8 silica sand, which was a dispersant, was mixed and mixed with the same commercially available hand mixer as in the above-mentioned Examples to prepare a comparative molded body. .

Then, when the physical properties similar to those of the examples were examined for each of the 10 comparative molded bodies, each of the 10 molded bodies showed significantly different data, and it became clear that the above mixture was not homogeneous. .

<< Effects of the Invention >> As described in detail above, according to the present invention, the following effects can be achieved.

(1) Due to the action of short carbon fibers, it is possible to provide a fiber-reinforced coating material that is excellent in repeated impact load resistance even with thin coating.

(2) Even with thick coating, since the amount of heat generated and the amount of shrinkage are small, cracking does not occur.

(3) Bending / compressive strength and maximum elongation are increased, which not only enhances deformability but also significantly improves chemical resistance and durability, making it suitable for factory floors, road pavements, and other general coating materials. Very suitable.

(4) It has excellent workability, has super-fast curing property, and has low-temperature workability, and is extremely excellent as a coating material such as a floor material. That is, when the carbon fibers and silica sand as the dispersant are mixed, the carbon fibers and silica sand can be uniformly and easily dispersed and mixed, and the dispersion mixture thereof is mixed with mortar or concrete in a resin. A mixture of
Alternatively, it can be uniformly dispersed in the resin or the like when further mixed with either the resin alone, that is, the resin matrix in the second step. Therefore, at the time of these two stages of mixing, the power of each mixing operation is extremely small and sufficient, and the mixing time is short.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Junichi Fujita 4-1-2 Hirano-cho, Chuo-ku, Osaka City, Osaka Prefecture Osaka Gas Co., Ltd. (72) Inventor Miki Aoyama 4-640, Shimoseido, Kiyose-shi, Tokyo Incorporated company Obayashi Institute of Technology (72) Inventor Yoshimasa Hayashi, 4-640 Shimoseido, Kiyose-shi, Tokyo Stock company Obayashi Institute of Technology (72) Inventor, Haruka Ogawa 4-640, Shimoseido, Kiyose-shi, Tokyo Obayashi Technical Research Institute (72) Inventor Toru Okui 4-33 Kitahama East, Chuo-ku, Osaka City, Osaka Prefecture Obayashi Corporation Main Store (72) Inventor Kazutoshi Tsutsumi 2-3 Kandaji-cho, Chiyoda-ku, Tokyo Co., Ltd. Obayashi Tokyo Head Office (56) Reference JP 64-33037 (JP, A) JP 63-17245 (JP, A) JP 63-138098 (JP, A) JP Flat 1-192752 (JP, A)

Claims (2)

(57) [Claims] 1. A dispersion of silica sand as a dispersant having a particle size of 0.3 mm or less and carbon fibers having a fiber length of 10 mm or less,
A mixture of resin and mortar or concrete, or a resin alone, and the carbon fiber content is 1 wt% or more with respect to the silica sand and 10 wt% or less with respect to the resin. A fiber-reinforced coating material characterized in that 2. Silica sand as a dispersant having a particle size of 0.3 mm or less and carbon fibers having a fiber length of 10 mm or less are dispersed and mixed as a first step without adding water, and the dispersion mixture is then mixed with a mortar resin. Alternatively, a method for producing a fiber-reinforced coating material, which comprises mixing the mixture with concrete or a resin alone as a second step.